I have a model based on a real production line, a few workcells with a few workstations inside each cell.
Robots move parts inside each workcell and AGV's move parts from each workcell to the next one.
In the real word there is a request to have some maintenance/setup work. This happening every x hours and last for xx minutes.
The operator is stepping to the workstation, after the last part completion he start the required work.
It includes tool changes, greasing, recalibration, run a first shot to make sure the workstation run correclty again and can continue the normal production. To simplify I wrap up all this work into single service.
I started with a failure which I can define first start time, any further start time and duration. I have a failure importer to get the worker move the the workstation.
This works fine....
I experience the situation the workcell get stuck when the operator does the setup/maintenance work.
I don't know if the last part has been completed. It stays in the machine.
What is the correct way to implement this service in the plant simulation ?
I have a chart which shows the operator occupation.
For the real world, people like to know how many service worker are required to run the production line.
When simulating production lines you are ( apart form others)
interested in the simulated performance ( jobs per hour / per shift / per day).
The impact of the maintenance (time) is usually considered in the net production time ,
where the maintenance(time) has already been excluded from.
You therefore do not simulate the maintenance impact as the impact
is already considered through the (reduced) net production time.
The maintenance operator count can be individually calculated through necessary tasks
and is not determined through the simulation.
To in increase the production time, maintenance tasks often are "squeezed" into the pauses / end of shift.
or automated like tip dressing- /changing.
Emptying the production line is usually done before a production batch change
What is your simulation target ?
Do you have to consider the maintenance in this level of detail ?
the simulation target is to help setting up and optimizing the production in the real world.
I have a table with the real process times, they will also provide me the part transiting times inside each wortcell and from workcell to workcell.
Management want to know from the simulation:
- what is the occupation level of this operator (worker) who is:
bringing raw material to the production line, carries away part sets after completion, does the setup/maintenance work.
I have added a chart which shows a pie of the worker occupation (this is very efficient view).
- how the production efficiency be improved (adding, changing locations, re-using machinees/ workstations etc...)
this was a misunderstanding.
It sounded like if you added a chart to your post to highlight
the model performance improvements.
In any case for estimating the operator utilization
the usage of yamazumi charts is helpful.
The data required for the charts is probably the same data
you use as input for operator simulation e.g. walking paths of operators
and operator processing times.
took some time ... had to work on other projects.
As you recommend to use a Yamazumi chart, I am unable to find this type of chart in tecnomatix.
There is no property to switch the 'Chart' to a speciific type.
I am using V13.1, probably you have a higher version.
Yamazumi charts are not part of Plant Simulation
But are used manually determine the Worker utilization (agmonst other data)
What I am on about, is although oyf course you can simulate the operator behaviour
it sometimes maybe simpler/ quicker to manually calculate it with the same / similiar input data.
I can use the existing data an calculate what I need, I will work on this later.
To return to my original question:
What is the correct way to implement service/maintenance in the plant simulation ?
I started with a failure, where I can define first start time, any further start time and duration. I have a failure importer to get the worker move the the workstation....
The intended way to define setups including worker is
Setting the failure as a Set-up interruption should also work but the Set-up statistics will
logged under failure statistics.